Fluke OPG1-30000-AF User Manual

T.O. 33A6-4-30-1

OPG1-30000-AF™

Oil Pressure Generator/Controller

Operation and Maintenance Manual

NSN 6685-01-470-8667

(1 of 2)

1 August 2000

OPG1™ Operation and Maintenance Manual

High pressure liquids and gases are potentially hazardous. Energy stored in these liquids and gases can

be released unexpectedly and with extreme force. High pressure systems should be assembled and operated only by personnel who have been instructed in proper safety practices.

Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of DH Instruments, Inc. 4765 East Beautiful Lane Phoenix AZ 85044-5318 USA.

DH Instruments makes sincere efforts to ensure accuracy and quality of its published materials; however, no warranty, expressed or implied, is provided. DH Instruments disclaims any responsibility or liability for any direct or indirect damages resulting from the use of the information in this manual or products described in it. Mention of any product or brand does not constitute an endorsement by DH Instruments of that product or brand. This manual was originally composed in English and was subsequently translated into other languages. The fidelity of the translation cannot be guaranteed. In case of conflict between the English version and other language versions, the English version predominates.

DH Instruments, DH, DHI, OPG1, OPG1-30000-AF, RPM3, RPM3/HPMS, PG7000 and CalTool are trademarks, registered and otherwise, of DH Instruments, Inc.

Swagelok is a registered trademark of the Swagelok Company. Teflon is a registered trademark of the 3M Corporation.

Document No. 550114-01 20000120 Printed in the USA

OPG1™ Operation and Maintenance Manual

AABBLLEE

TABLE OF CONTENTS ............................................................................... i

TABLES...................................................................................................

FIGURES .................................................................................................

ABOUT THIS MANUAL .............................................................................

1. INTRODUCTION....................................................................................

1 . 1 PRODUCT OVERVIEW .............................................................................................................................1

1 . 2 SPECIFICATIONS .....................................................................................................................................2

1 . 3 INSTRUMENT LAYOUT ............................................................................................................................3

1.3.1 FRONT PANEL ..................................................................................................................................................3

1.3.2 OVERALL DIMENSIONS...................................................................................................................................

1.3.3 SYSTEM SCHEMATIC.......................................................................................................................................

2. INSTALLATION..................................................................................... 7

2.1 UNPACKING AND INSPECTION ..............................................................................................................7

2.1.1 REMOVING FROM PACKAGING......................................................................................................................7

2.1.2 INSPECTING CONTENTS .................................................................................................................................

2 . 2 SITE REQUIREMENTS..............................................................................................................................8

2 . 3 INITIAL SETUP .......................................................................................................................................... 9

2.3.1 PREPARING FOR OPERATION .......................................................................................................................9

2 . 4 POWER UP AND VERIFICATION........................................................................................................... 13

2.4.1 APPLY PNEUMATIC POWER (DRIVE AIR) ...................................................................................................13

2.4.2 ADJUST HYDROPNEUMATIC PUMP DRIVE AIR PRESSURE.....................................................................

2.4.3 CHECK PROPER OPERATION OF HYDROPNEUMATIC PUMP AND LEAK CHECK ................................

2.4.4 PRECAUTIONS TO TAKE BEFORE GENERATING PRESSURE/SAFETY CONSIDERATIONS ................

2 . 5 SHORT TERM SHUT-DOWN ..................................................................................................................18

2 . 6 LONG TERM STORAGE AND SHIPPING ..............................................................................................

2.3.1.1 SET UP THE OPG1-30000-AF ..........................................................................................................

2.3.1.2 CONNECT PNEUMATIC POWER (DRIVE AIR) ...............................................................................

2.3.1.3 MAKE HYDRAULIC PRESSURE INTERCONNECTIONS ..............................................................

2.3.1.4 CONNECTING TO A DEVICE UNDER TEST .................................................................................

2.4.3.1 STEP ONE: PURGING AIR FROM THE HYDRAULIC PUMP CIRCUIT........................................

2.4.3.2 STEP TWO: GENERATING A PRESSURE ...................................................................................

NTTEE

NTTSS

iii iii

4 5

9 11 12

14 14

14 15

3. GENERAL OPERATION ....................................................................... 19

3 . 1 OPERATING PRINCIPLE........................................................................................................................ 19

3 . 2 OPERATIONAL FUNCTIONS .................................................................................................................

3.2.1 SETTING INLET PRESSURE, DRIVE SET REGULATOR ADJUSTMENT....................................................21

3.2.2 ROUGH PRESSURE GENERATION/CONTROL, INLET AND OUTLET VALVE OPERATION ....................

3.2.3 FINE PRESSURE ADJUSTMENT, PDVV (+) AND (-) VALVE OPERATION .................................................

3.2.4 CONNECTING A DEVICE UNDER TEST (DUT).............................................................................................

3.2.5 PURGING AIR FROM THE DUT/SYSTEM UNDER TEST..............................................................................

3.2.6 MEASUREMENT REFERENCE LEVEL WHEN VENTED ..............................................................................

3 . 3 TYPICAL OPERATING SEQUENCE FOR A COMPLETE CALIBRATION OR TEST............................26

4. MAINTENANCE ADJUSTMENTS AND CALIBRATION ............................. 27

4 . 1 OVERVIEW ..............................................................................................................................................27

22 23 24 24 25

OPG1™ Operation and Maintenance Manual

4 . 2 FILLING THE TANK ................................................................................................................................ 28

4 . 3 REPLACING OIL AND PURGING CONTAMINATED OIL...................................................................... 29

4 . 4 PRIMING THE HYDROPNEUMATIC PUMP ...........................................................................................30

4.4.1 PRIMING THE HYDROPNEUMATIC PUMP BY SYRINGE INJECTION ........................................................ 30

4.4.2 INTERNAL PURGE OF HYDROPNEUMATIC PUMP .....................................................................................

4 . 5 CLEANING/REPLACING DRIVE AIR FILTER ELEMENTS....................................................................32

5. TROUBLESHOOTING .......................................................................... 33

6. APPENDIX..........................................................................................

6 . 1 WARRANTY STATEMENT......................................................................................................................35

GLOSSARY............................................................................................. 37

OPG1™ Operation and Maintenance Manual

AABBLLEES

Table 1. OPG1-30000-AF Parts List ....................................................................................................... 7

Table 2. Pneumatic Power (Drive Air) Requirements ...........................................................................

Table 3. OPG1 Troubleshooting Checklist............................................................................................

Table 4. DHI Authorized Service Providers...........................................................................................

Figure 1. Front Panel ................................................................................................................................ 3

Figure 2. Front and Side Views with Dimensions .....................................................................................

Figure 3. System Schematic.....................................................................................................................

Figure 4. Connecting OPG1-30000-AF to an RPM3/HPMS...................................................................

Figure 5. System Schematic...................................................................................................................

Figure 6. Front Panel ..............................................................................................................................

Figure 7. PDDV Position Indicator ..........................................................................................................

Figure 8. Fluid Head Level When Vented, INLET Valve Open ..............................................................

Figure 9. Oil Tank ...................................................................................................................................

Figure 10. Hydropneumatic Pump............................................................................................................

Figure 11. Drive Air Filters ........................................................................................................................

IIG

URREESS

10 33 36

5 11 20 21 23 25 28 31 32

OPG1™ Operation and Maintenance Manual

This manual provides the user with the information necessary to operate an OPG1-30000-AF Hydraulic Pressure Generator/Controller. It also includes a great deal of additional information provided to help you optimize OPG1-30000-AF use and take full advantage of its many features and functions.

FOR THOSE OF YOU WHO “DON’T READ MANUALS”, GO DIRECTLY TO SECTION 2.3 TO SET

UP YOUR OPG1-30000-AF. READ SECTION 2.4.4 AND GO TO SECTION 3.3. THIS WILL GET YOU UP AND RUNNING QUICKLY WITH MINIMAL RISK OF CAUSING DAMAGE TO YOURSELF OR YOUR OPG1. THEN… WHEN YOU HAVE QUESTIONS OR START TO WONDER ABOUT ALL THE GREAT FEATURES YOU MIGHT BE MISSING, GET INTO THE MANUAL!

(CAUTION) is used throughout the manual to identify user warnings and cautions.

(NOTE) is used throughout the manual to identify operating and applications advice and

additional explanations.

BBO

UTT

HIISS

Manual Conventions

AAN

UAALL

OPG1™ Operation and Maintenance Manual

1. INTRODUCTION

1.1 PRODUCT OVERVIEW

The OPG1-30000-AF Hydraulic Pressure Generator/Controller is a stand alone, pressure generating and controlling component intended to be used as the pressure source and means of pressure adjustment in hydraulic calibration and test systems. It is capable of both generating and precisely adjusting pressure from atmosphere to 200 MPa (30 000 psi).

OPG1-30000-AF combines the versatility, speed and reliability of direct operator control with the convenience and effort-free operation of automation. It is the standard pressure generating and control component in an HGC-30000-AF Hydraulic Gauge Calibration system as well as in a PG7302 piston gauge system.

OPG1-30000-AF includes an on-board hydropneumatic pump to fill the system under test and generate pressures up to 200 MPa (30 000 psi). Two progressive needle valves control the inlet of pressure from the pump to increase pressure and outlet back to the reservoir to decrease pressure. Very fine pressure adjustment and generation of small pressure excursions is accomplished using a Pneumatically Driven Variable Volume (PDVV) with push button control. Pneumatic power (drive air) of up to 850 kPa (120 psi) is needed to drive the hydropneumatic pump and PDVV.

OPG1™ Operation and Maintenance Manual

1.2 SPECIFICATIONS

Electrical Power Requirements None

Pneumatic Power Requirements Clean, dry, compressed air @ 50 slm (1.8 scfm) flow. Maximum

pressure needed depends on maximum oil pressure desired:

- 70 MPa (10 000 psi): 550 kPa (80 psi)

- 140 MPa (20 000 psi): 700 kPa (100 psi)

- 200 MPa (30 000 psi): 850 kPa (120 psi)

Operating Temperature Range 10 to 45 °C

Weight 27 kg (60 lb)

Dimensions 30 cm H x 30 cm W x 53.5 cm D (11.75 in. x 11.75 in. x 21.0 in.)

(Height: Top of tank which is 8.5 cm (3.3 in.) above the top instrument surface)

Pressure Range

0 to 200 MPa (30 000 psi)

Maximum output pressure depends on pneumatic power supply (see above)

Operating Medium Di-2-Ethyl Hexyl Sebacate (same as PG7302 piston gauge) and

other non-corrosive oils

Pneumatic Power Connection(s) 1/4 in. NPT F (can be configured into two independent

connections, one for pump drive and one for variable volume drive)

Hydraulic Test Connections (3) DH500 F test connections (one at back of either side and one

on top of reservoir)

NOTE: DH500 is a gland and collar type fitting for 1/4 in. (6.35 mm) coned and left hand threaded tube. DH500 is equivalent to AE F250C, HIP HF4, etc.

Reservoir Capacity 200 cc (12 in

Pneumatically Actuated

1 cc (0.06 in

)

Variable Volume (PDVV) Displacement

Typical Pressure Generation Time (0 to 200 MPa/30 000 psi)

Less than 12 seconds

into air purged 50 cc volume

OPG1™ Operation and Maintenance Manual

1.3 INSTRUMENT LAYOUT

1.3.1 FRONT PANEL

The front panel provides all of the controls and indications needed to set and adjust pressure.

1. PDVV Drive Air/Test Oil Pressure Gauge

2. PDVV Piston Position Indicator

3. Pump Drive Air/Inlet Oil Pressure Gauge

4. Pump Drive Air Set Regulator

5. Test Inlet Valve Knob

6. PDVV Increase Fast and Slow Buttons

7. PDVV Decrease Fast and Slow Buttons

8. Test Outlet Valve Knob

Figure 1. Front Panel

OPG1™ Operation and Maintenance Manual

1.3.2 OVERALL DIMENSIONS

Figure 2. Front and Side Views with Dimensions

OPG1™ Operation and Maintenance Manual

1.3.3 SYSTEM SCHEMATIC

1. Pump Drive Air Set Regulator 11. Fast and Slow PDVV Decrease Valves

2. Hydropneumatic Pump 12. Fast and Slow PDVV Increase Valves

3. Tank 13. PDVV DRIVE Air Connection

4. Top TEST Connection 14. Common DRIVE Air Connection

5. Oil Return Overflow Tube 15. DRIVE Air Filters

6. Right Side TEST Connection 16. PUMP DRIVE Pressure Gauge

7. Left Side TEST Connection 17. PDVV Plunger Position Indicator

8. Test Outlet Valve 18. PDVV DRIVE Pressure Gauge

9. Test Inlet Valve 19. PDVV DRIVE to PDVV Connection

10. Pneumatically Drive Variable Volume (PDVV)

20. Oil Filter

Figure 3. System Schematic

OPG1™ Operation and Maintenance Manual

OOTTEES

OPG1™ Operation and Maintenance Manual

2. INSTALLATION

2.1 UNPACKING AND INSPECTION

2.1.1 REMOVING FROM PACKAGING

OPG1-30000-AF is delivered, along with its standard accessories in a corrugated container with corrugated and polyurethane inserts to hold it in place.

Remove the OPG1 and its accessories from the shipping container and remove each element from its protective plastic bag.

Retain the packaging in case of future OPG1 shipments.

2.1.2 INSPECTING CONTENTS

Check that all items are present and have NO visible damage. Verify the items received against the parts list in Table 1.

Table 1. OPG1-30000-AF Parts List

DESCRIPTION PART NO.

OPG1-30000-AF Instrument 401602

Operation and Maintenance Manual 550114

Accessories: 401580

Mat, Top Surface Protection 122998 Sebacate (synthetic oil), 1 qt. 400503 Syringe, 10 cc 102817 O-ring, Brown Viton, 2-104 102758

Interconnections Kit: 401603

1 ea. Nipple, 2.75 in., DH500 100207 1 ea. Nipple, 6 in., DH500 100208 1 ea. Nipple, 24 in., DH500 100270 1 ea. Elbow, 24 in., DH500 123136 1 ea. Adaptor, DH500 F x 1/4 in. NPT M 102889 1 ea. Adaptor, DH500 F x 1/4 in. NPT F 102820 1 ea. Adaptor, DH500 F x 37 degree (AN4) Mi 102888 2 ea. Gland, DH500 100271 5 ea. Collar, DH500 100201

OPG1™ Operation and Maintenance Manual

2.2 SITE REQUIREMENTS

The OPG1-30000-AF is typically delivered as part of an HGC-30000-AF hydraulic gauge calibrator that includes an RPM3/HPMS-A30000/A6000-AF that has its own Operation and Maintenance Manual.

When selecting and preparing a site to set up the OPG1-30000-AF and HGC-30000-AF system, the following should be considered:

• Bench Stability: The OPG1 weighs about 27 kg (60 lb). The RPM3/HPMS-A30000/A6000-AF

weighs about 10 kg (22 lbs). Consider the combined weight and that of other components, including possible items to be tested, when selecting a bench.

• Footprint: The HGC-30000-AF system requires a minimum bench space approximately 84 cm

(33 in.) wide and 60 cm (24 in.) deep.

• Location of Other Components: Plan the space required and a convenient layout for the

complete system in which OPG1 is the pressure generation/control component.

If the OPG1 is to be used with an RPM3/HPMS, the OPG1 accessories include the hardware necessary for setting up in a standard configuration (see Sections 2.1.2, 2.3.1.3). These allow the RPM3/HPMS to be placed to the right or the left of the OPG1, as desired.

The interconnecting tubing and fittings provided with the OPG1 accessories can also be used to connect to other systems. If interconnections other than the OPG1 accessories are used, select tubing and fittings rated to handle the maximum pressures that will be generated. OPG1 hydraulic fittings are all DH500 (equivalent to AE F250C, HIP HF4, etc.). The female DH500 fittings are delivered with gland nuts and plugs installed. Collars are included in the accessory kit.

If you do not plan to use OPG1’s top TEST port, consider where a device or system under test (DUT) will be connected.

• Pressure Supply: Plan the pneumatic power to OPG1. This requires two separate sources:

a) 850 kPa (120 psi) from an N2 or Air bottle connected to the rear left of the OPG1; b) 620 kPa (90 psi) non-lubricated compressed air connected to the rear right of the OPG1 (see Section 2.3.1.2). The connections are 1/4 in. NPT female.

• System Interconnections: Plan the interconnections between OPG1 and other components in

the system. Minimizing the volume and maximizing the mass of all interconnecting elements will reduce pressure generation and stabilization time. An extra nipple is provided in the OPG1 interconnection accessories for possible connection to an existing oil/air separator (see Section 2.3.1.3).

ALWAYS use external tubing and fittings rated for pressures equal to or greater than the

maximum pressure OPG1 will be used to generate.

+ 30 hidden pages

Fluke OPG1-30000-AF User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. INTRODUCTION

1.1 PRODUCT OVERVIEW

1.2 SPECIFICATIONS

1.3 INSTRUMENT LAYOUT

1.3.1 FRONT PANEL

1.3.2 OVERALL DIMENSIONS

1.3.3 SYSTEM SCHEMATIC

2. INSTALLATION

2.1 UNPACKING AND INSPECTION

2.1.1 REMOVING FROM PACKAGING

2.1.2 INSPECTING CONTENTS

2.2 SITE REQUIREMENTS